Thermally insulated industrial freezer structure and system

ABSTRACT

A freezer structure ( 12 ) includes a floor structure ( 20 ), side walls ( 22 ) and a ceiling ( 24 ), each of which includes a substantially hollow inner or upper layer or zone ( 30 ) behind or beneath which is disposed an intermediate layer or zone ( 32 ) substantially filled with insulating filler material and a bottom or outer layer or zone ( 34 ) that is substantially hollow. A monitoring system ( 16 ) monitors the temperature, moisture level and pressure of a substantially dry gas circulating through the first layer or zone to maintain the first layer or zone in substantially dry condition.

FIELD OF THE INVENTION

The present invention relates to an industrial freezer structure andsystem for the cold storage of food and other goods.

BACKGROUND

Enclosures for industrial freezers in food processing facilities havealways been a source of concern when it comes to hygienic design. Theoriginal caulked, sealed, interior panels still in use today requireconstant inspection and maintenance of the joints to keep water andproduct debris from entering the insulated spaces. Industrial freezershave been constructed with a fully welded stainless steel insulatedenclosure. This has provided a significant improvement over priorfreezers due to no longer having to rely on caulked joints for sealingthe interior panels of the freezer relative to each other, although,over time, even this design develops leaks that allow moisture tomigrate into the sealed insulated spaces. The freezer structure of thepresent disclosure seeks to address this issue with the fully sealwelded stainless steel freezer design.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features ofthe claimed subject matter, nor is it intended to be used as an aid indetermining the scope of the claimed subject matter.

The present disclosure provides a freezer structure wherein theinsulation is fully sealed in a separate space not in direct contactwith the inside surfaces of the freezer enclosure. In addition, aseparate, sealed chamber is disposed between the inside enclosuresurface and the sealed insulated space of sufficient size to enable theseparate sealed chamber to be visually inspected, monitored withsensors, conditioned, cleaned, and sanitized.

A thermally insulated floor structure for an industrial freezer includesa first zone of substantially hollow configuration, configured tosupport a load-bearing deck thereon, and a second zone substantiallycoexistent with the first zone and substantially isolated from the firstzone. The second zone is substantially occupied by a thermally insulatedmaterial enclosed in a fluid-impervious envelope. The first zoneincludes at least one inlet through which a medium enters the first zonefor circulation therethrough, and at least one outlet through which thecirculation medium exits the first zone.

A thermally insulated floor structure wherein the fluid medium includesa gas, a gas mixture to assist in maintaining the first layer insubstantially dry condition, a fluid to sterilize the first layer and/ormaintain the first layer in sterilized condition, or a fluid to assistin thawing the ice formed in the first layer.

The thermally insulated floor structure wherein the second zone issubstantially sealed from the interior and the fluid-impervious envelopeused to enclose the thermally insulating material comprises a foil-typematerial.

The thermally insulated floor structure further including a third zonedisposed along the second zone opposite to the location of the firstzone. A third zone being substantially closed from the environment anddisposed beneath the second zone.

A thermally insulated load-bearing floor structure includes a firstlayer constructed to define a hollow chamber and load-bearing members tosupport an overhead load-bearing deck, and a second layer underlying thefirst layer and constructed to support the first layer, with the secondlayer being substantially occupied by thermally insulated material. Thefloor structure is constructed to substantially isolate the first layerfrom the second layer. In addition, a circulation system is provided tocirculate selected fluids through the first layer, with such fluidsselected from a group consisting of a gas or gas mixture to assist inmaintaining the first layer in substantially dry condition, a fluid tosterilize the first layer and/or maintain the first layer in sterilizedcondition, or a fluid to assist in thawing ice formed in the firstlayer. A monitoring system is provided for monitoring one or more of thetemperature, pressure, and moisture levels in the substantially hollowfirst layer.

The thermally insulated load-bearing floor system wherein thecirculating fluids comprise one or more of dry, low dew point air;steam; air together with an anti-bacterial agent; or an inert gas.

The thermally insulated load-bearing floor system wherein the monitoringsystem sensing one or more of the dew point of the fluid within thefirst layer, the volume of the fluid circulating through the firstlayer, and the pressure of the fluid circulating through the firstlayer.

The thermally insulated load-bearing floor system, wherein the floorstructure further includes a third layer beneath the second layer, thethird layer extending between the underside of the second layer, and thesurface beneath the second layer. In addition, the third layer is formedby spacers underlying the second layer.

A freezer constructed from a first layer adjacent the interior of thefreezer and configured to define a substantially hollow chamber and asecond layer disposed outwardly of the first layer. The second layer issubstantially occupied by thermally insulating material. In addition,the second layer is substantially isolated from the first layer. A fluidcirculation system is provided to circulate a substantially dry gas forthe first layer at a flow rate to maintain the first layer insubstantially dry condition. In addition, a monitoring system isprovided to monitor one or more of the temperature, pressure, andmoisture level within the first layer.

The freezer wherein the first and second layers comprise the floorstructure of the freezer. The freezer also including upright walls thatjoin to the floor structure such that the interior of the upright wallsare in fluid flow communication with the interior of the first layer ofthe floor structure.

The freezer, further including a third layer disposed beneath the secondlayer. The third layer including spacer members that underlie the secondlayer to space the second layer above the surface beneath the secondlayer.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same become betterunderstood by reference to the following detailed description, whentaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a representative schematic view of the enclosure system of thepresent disclosure;

FIG. 2 is an isometric view, partially in schematic, of a freezerstructure according to the present disclosure;

FIG. 3 is an isometric view of the floor structure of the freezerstructure of the present disclosure;

FIG. 4 is an exploded isometric view showing portions of the componentsof the floor structure of FIG. 3;

FIG. 5 is an exploded isometric view showing additional components ofthe floor structure of FIG. 3;

FIG. 6 is an isometric exploded view showing additional components ofthe floor structure of FIG. 3;

FIG. 7 is an exploded isometric view of FIG. 3, showing additionalcomponents of the floor structure of FIG. 3;

FIG. 8 is an enlarged fragmentary elevational view of components of thefloor structure shown in FIGS. 6 and 7;

FIG. 9 is an enlarged, partial cross-sectional view of the floorstructure shown in FIG. 3;

FIG. 10 is an enlarged, partial cross-sectional view of the floorstructure shown in FIG. 3; and

FIG. 11 is an enlarged, partial cross-sectional view of the floorstructure shown in FIG. 3 as well as a corresponding wall section.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings, where like numerals reference like elements, is intended as adescription of various embodiments of the disclosed subject matter andis not intended to represent the only embodiments. Each embodimentdescribed in this disclosure is provided merely as an example orillustration and should not be construed as preferred or advantageousover other embodiments. The illustrative examples provided herein arenot intended to be exhaustive or to limit the disclosure to the preciseforms disclosed. Similarly, any steps described herein may beinterchangeable with other steps, or combinations of steps, in order toachieve the same or substantially similar result.

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of exemplary embodiments ofthe present disclosure. It will be apparent to one skilled in the art,however, that many embodiments of the present disclosure may bepracticed without some or all of the specific details. In someinstances, well-known process steps have not been described in detail inorder not to unnecessarily obscure various aspects of the presentdisclosure. Further, it will be appreciated that embodiments of thepresent disclosure may employ any combination of features describedherein.

Referring initially to FIG. 1, freezer system 10 includes a freezerstructure 12 and a control system 14 for controlling the operation inthe freezer system. A monitoring system 16 monitors the operationalparameters for the freezer system, including the temperature thereof,and sends this information to the control system. The control systemcontrols the operation of a circulation system 18 to circulate variousfluids through the freezer system for the control of the freezer systemand the maintenance thereof. These major systems of the freezer system10 are more fully described below.

Next, referring to FIGS. 2, 3 and 11, the freezer structure 12 includesa floor structure 20, sidewalls 22, and a ceiling 24. One or more doors,not shown, can be incorporated into the sidewall. The floor structure20, sidewalls 22, and ceiling 24, and the door(s) can be constructedsimilarly. As such, the following description will focus primarily onthe construction of the floor structure 20.

Referring specifically to FIGS. 9, 10 and 11, the floor structure inbasic form is composed of an upper layer or zone 30, an intermediatelayer or zone 32, and a bottom layer or zone 34. These three layers areconstructed as a unitary structure.

Referring to FIG. 4, the floor structure 20 includes a pan structure 40having a flat base surface 42, with parallel sidewalls 44 extendingupwardly from the opposite sides of the base surface 42, and parallelsidewalls 46 extending upwardly from the other of the two opposite edgesof the base surface 42. An outwardly extending rim 48 extends outwardlyfrom the upper edges of the sidewalls 44 and 46. Also, a center flangeor rib 50 extends beneath the pan structure 40, parallel to thesidewalls 44. The center rib 50 may be continuous below the base surface42, or instead may be disposed in sections beneath and across the basesurface. In the pan structure 40, the intersection between the sidewalls44 and 46 with the base surface 42 forms a sealed joint, not allowingany fluids to pass therebetween. The same is true at the junctures ofthe sidewalls forming the corners of the pan structure 40.

Although shown in FIG. 4 as constructed of two halves joined together,the pan structure 40 can be constructed as a singular unit. Also, thepan structure could instead be of other constructions, such as of aseparate base 42 and separate side walls 44 and 46 that are joined atthe base.

As shown most clearly in FIGS. 3-7, openings 52 are formed in thesidewalls 44. Each such opening is defined by a circular hole formed inthe sidewalls 44 and a short throat 54 in communication with the opening52. Flange 56 encircles the end of the throats 54 opposite while opening52.

Referring to FIG. 4, a plurality of spaced apart spacer members 60extend across the base surface 42 of the pan structure 40. These spacermembers 60 can be of various constructions, including in the form ofshallow channels, planks, shallow tubular members, etc. Also, the spacermembers can be of solid construction or can be of pervious construction,for example, perforated, or composed of expanded metal.

As shown in FIG. 5, a layer of thermal insulation 66 overlies the spacermembers 60. The thermal insulation layer may be in the form of a singlemember or may be composed of a plurality of sections. Also, theinsulation layer may be of various compositions, including composed of adense, closed cell material to enable the insulation layer to alsoperform a load-bearing function. In this regard, the insulation layercan be of various compositions, for example, composed ofpolyisocyanurate, polyurethane, and polystyrene of a desired density.The composition and/or thickness of the thermal insulating layer 66 maybe designed to achieve a desired “R” rating for the insulation.

To assist in keeping the thermal insulation separate and isolated fromthe rest of the floor structure 20, the thermal insulation may beencased or wrapped in an envelope 68 (see FIGS. 9-11) of tough,impervious material, for example, foil or Mylar. As a consequence, evenif there is a breach in the floor structure 20, any liquids or fluidsthat may flow through the breach will not reach the thermal insulationlayer 66, thereby avoiding contamination of the insulation layer.

A top sheet or layer 70 overlies a top of the thermal insulation layer66. This top layer may be composed of a solid metallic structuralmaterial. The top layer may be of other compositions, such as composedof a honeycomb structure or other structure, but with a continuous upperand lower surface. The perimeter of the top layer is sealed against thesidewalls 44 and 46 of the pan structure 40, for example, by welding. Asa consequence, the thermal insulation layer 66 forms a sealedconstruction from the remainder of the floor structure. This insulationlayer forms the intermediate layer 32 of the floor structure 20.

The relatively narrow space or layer 34 below the thermal insulatinglayer 66, created by a spacer member 60, keeps the insulation layerspaced from the base surface 42 of the pan structure 40. As aconsequence, the second layer is subjected to reduced thermal stressrelative to if the thermally insulating layer 66 were in direct contactwith base surface 42. Moreover, as discussed more fully below, thisbottom layer 34 can be monitored for temperature and/or other physicalparameters. Such monitoring can indicate whether the insulation layer 66is functioning properly or not.

Referring to FIGS. 6-10, above intermediate layer 32, the floorstructure 20 includes the upper layer 30 formed between the top sheet orlayer 70 and a load carrying deck 80 that is coplanar with the rim 48 ofpan structure 40. The deck is supported above the top sheet or layer 70by a series of load bearing support members 82 that extend across thetop sheet or layer 70 parallel to sidewalls 46. The support members 82support the deck 80 above the top sheet or layer 70. Although threesupport members 82 are shown in parallel, spaced apart relationship fromeach other, a different number of support members may be utilized.

As most clearly shown in FIGS. 6, 8 and 10, the support members aregenerally in the shape of a channel. However, the lower flange isconfigured to define spaced-apart scallops 83 thereby to form a seriesof spaced-apart pads 84 that bear against the top surface of top sheetor layer 70. The scallops 83 extend upwardly a distance along the web 85portion of the support member to form spaced apart longitudinal openings86 along the length of the support members. The scalloped shape of thelower portion of the support members 82 reduces the contact surfacebetween the support members and the top sheet or layer 70, which allowsfor easier welding of the support member to the top layer. Thisstructure, by forming openings 86, also allows for mixing of airthroughout the hollow upper layer 30.

As also shown in FIGS. 8 and 10, at the ends of the support members 82,the web sections 85 are angled inwardly in a downward direction. Thisreduces or minimizes cold bridging between the support member 82 and theexterior skin of the freezer enclosure defined by the sidewalls 44 ofpan structure 40.

Although the support members 82 are illustrated as being of a channelshape, other shapes for the support members may be utilized. Forexample, the support members may be of a Z-shaped cross-section or anI-shaped cross-section.

Further, other or additional types of support members may optionally beutilized in conjunction with the support members 82. For example, aseries of short cylindrical columns 90 may be spaced apart about thearea of the top sheet or layer 70 to span between the top layer and theunderside of the deck 80, see FIG. 7. To increase the load bearing areaof the columns 90, the ends of the columns can be capped and/or thecolumn can include flanges extending radially outwardly from one or bothof the upper and lower ends of the columns. The columns can be held inplace by numerous means, including by welding.

Referring to FIGS. 7, 8 and 10, a plurality of ribs or bars 92 extendbeneath the deck 80, transversely to the support members 82. The bars 92are welded or otherwise securely attached to the underside of the deck80. The bars 92 closely engage within transverse slots 94 formed in theupper portion of the support members 82. As will be appreciated, bars 92provide support for the deck in the direction transversely to the lengthof the support members 82.

It will be appreciated that the load carried by deck 80 is transferreddownwardly through the support members 82 to the top sheet or layer 70and then ultimately to the thermal insulating layer 66. To assist incarrying this load, a plurality of high density plastic rods or blocks91 may be extended through the insulating layer 66 and through spacers60 at locations disposed beneath the support members 82, and inparticular the pads 84 of the support members. The blocks 91 may also beplaced beneath the columns 90 described above. As a consequence loads onthe deck 80 can be transmitted directly to the floor 42 of the panstructure 40. Blocks or rods 91 can be composed of a minimal thermalheat transfer material, such as PEEK or UHMW. These blocks or rods helpensure that the load from the deck 80 is transmitted down to the base 42of the floor structure. Moreover, minimal thermal heat transfer willoccur through the blocks or rods 91 and to the spacer member 60 or panbase surface 42.

As noted above, the thermal insulating layer 66 is encased in anenvelope 68 of foil or other suitable material. This envelope iscompletely sealed. Accordingly, the areas in which the load blocks orrods 91 extend through the thermal insulating layer 66 are also sealedwith foil tape or Mylar tape, or other appropriate sealing tape.

The floor structure 20 may be supported above the installation locationof the freezer structure 12 by various means. As shown in FIGS. 4 and 9,a series of perimeter channel members 100 extend around the perimeter ofthe underside of the pan structure 40. Also two spaced-apart transversechannel members 102 extend across the underside of the pan structure 40to support the interior of the pan structure. Of course, channel memberssimilar to members 100 and 102 may be disposed otherwise about theunderside of the pan structure 40. In addition, other support structuresmay be utilized in place of the channel members 100 and 102.

As shown in FIG. 11, a portion of a sidewall 22 is shown as extendingupwardly from the floor structure 20. The construction of the sidewall22 is very similar to that of a floor structure 20. As such, thecomparable components of the sidewall 22 are identified with the samepart numbers, but with a “prime” designation. As such, the constructionof the sidewalls 22 will not be repeated here.

However, it is noted that the sidewall 46′ of pan structure 40′ hasopenings 52′ therein so that the layer 30′ of the sidewall is in fluidflow communication with the upper layer 30 of the floor structure 20.This enables the circulation system 18 to also circulate dry air andother fluids through the layer 30′ of the sidewall 22, as described morefully below.

Although not shown, the freezer structure 12 can also include a ceiling24 constructed similarly to the floor structure 20 and sidewalls 22.Further, the ceiling 24 can be composed of a substantially hollow layersimilar to layers 30 and 30′, and such substantially hollow layer of theceiling can be in air flow communication with the substantially hollowlayers 30′ of the sidewalls. As a consequence, the substantially hollowlayers of the floor structure 20, sidewalls 22, and ceiling 24 can allbe in fluid/air flow communication with each other.

The side walls are seal-welded to the floor structure deck 80 and to theceiling 24, as well as to each other. As a result, the interior of thefreezer structure 12 is isolated from the substantially hollow layers 30and 30′.

Next, referring to FIG. 1, circulation system 18 is schematicallyillustrated as being capable of circulating different types of fluidsthrough the hollow upper/inner layers 30 and 30′ of the freezer system10. In this regard, during normal operations, very low dew point airfrom an air supply 120 is routed to openings 52 formed in the panstructure sidewall 44 via inlet line 122 connected to the air supply120. The air supply supplies the low dew point air at dew pointtemperature of about −30° F. Pressure Dew Point (PDP), to −75° F. PDP.The continuous volume of the air supplied by the circulation system issufficient to keep the floor structure, sidewalls, and ceiling of thefreezer structure 12 in dry condition, as well as free from iceformation and bacteria growth. Moreover, the constant purging of dry airthrough layers 30 and 30′ disrupts the convective heat transfer throughthese layers, thereby keeping the temperature therein substantiallyhigher than the surface directly above the layers 30 and 30′.

The temperature of the low dew point air from the air supply may bealtered depending on the temperature of the food or other work productentering the freezer structure 12, as well as the temperature, humidity,and other environmental conditions exterior of the freezer structure. Tothis end, the air supply system 120 is connected to and controlled bythe control system 14. The control system is capable of operating theair supply to provide both very low dew point air to the freezerstructure, but also to supply heated air to the freezer structure 12.This heated air can be used to melt any ice that may have formed withinthe floor structure 20, sidewalls 22, or ceiling 24, for example, if abreach or leak had occurred in the freezer structure, allowing moistureto enter the upper/inner layers 30 and 30′ of the freezer structure.

As also shown in FIG. 1, as an alternative to air, the circulationsystem 18 can instead circulate an inert gas from a gas supply 130through the floor and wall hollow layers 30 and 30′. Such inert gas maybe used instead of the low dew point air. Examples of such gases includenitrogen and carbon dioxide. The operation of the gas supply 130 is alsounder the control system 14.

The circulation system 18 includes the capability of adding ananti-bacterial agent to either the inert gas from gas supply 130 or theair from air supply 120 so as to prevent bacteria from forming/growingin the floor structure 20, sidewalls 22, or ceiling 24, or to kill orotherwise eliminate bacteria that may have formed within the interior ofthe floor structure, sidewalls, and/or ceiling. Examples of suitableanti-bacterial agents include chlorine dioxide, and ozone. As with theair supply 120 and gas supply 130, the antibacterial supply 136 iscontrolled by the control system 14.

The circulation system 18 is also capable of circulating steam throughthe hollow layers of the floor structure 20, sidewalls 22 and ceiling 24of the freezer structure. The steam may be provided by a steam supply140. The steam can be introduced into inlet line 122, or a steammanifold, not shown, can be used to inject the steam directly into thelayers 30 and 30′. The temperature and volume of the steam circulatedthrough the hollow layers 30 and 30′ is sufficient to readily killbacteria and other pathogens that may be located therein. To this end,there must be a sufficient supply of culinary quality dry steam at 30psig to raise the temperature of all surfaces in the space to 145° F.and maintain for a period of 15 minutes. As in the air supply 120, gassupply 130, and antibacterial agent supply 136, the steam supply 140 isalso controlled by control system 14.

Continuing to refer specifically to FIG. 1, monitoring system 16 isprovided to monitor specific conditions within the interior of thefreezer floor, sidewalls, and ceiling. In this regard, a temperaturesensor 150 is located within floor upper layer 30 to measure thetemperature therein. This temperature can verify that the freezer isoperating properly and also confirm the integrity of the floor above thehollow layer 30. The temperature sensor 150 is connected to the controlsystem 14.

Monitoring system 16 also includes a pressure sensor 156 located withinthe hollow upper layer 30 of the floor structure. Such pressure sensorcan also provide information regarding if there is a malfunction in theairflow through the upper layer 30 causing the pressure to rise abovethe safe limits of the structure. As with the temperature sensor, thepressure sensor is also connected to the control system 14.

The monitoring system 16 also includes a moisture sensor 158, locatedwithin the hollow layer 30, and/or a dew point sensor 160 to measure thedew point of the air entering layer 30. The moisture sensor and dewpoint sensor are both capable of indicating whether or not there is abreach in the integrity of the freezer flow, or if an icing condition ispresent within the follow layers 30 and/or 30′. As with the temperatureand pressure sensors 150 and 156, the moisture and dew point sensors 158and 160 are also connected to the control system 14. As set forth above,ideally, the cold dry air circulating through the hollow layers 30 and30′ is at about −30° F. pressure dew point (pdp) to −75° F. pdp. Thisair flow can be at about 2 cubic feet per minute (cfm) to a max of 8 cfmper 4 ft section of the floor space, where long dimension of the flooris divided into 4 ft sections.

Monitoring system 16 also includes a temperature sensor 170 for sensingthe temperature in the third layer or zone below the thermal insulationlayer 66. Temperature sensor 170 is used to measure this temperature.One reason for monitoring the temperature below the thermal insulatinglayer 66 is to determine if the freezer structure 12 is functioningproperly and/or there is a breakdown in the upper layer 30 and/orintermediate layer 32. For example, if the temperature in the bottomlayer 34, as measured by the sensor 170, is relatively low, there may bea breach in the upper layer 30 or perhaps a breakdown in the thermalinsulating layer 66.

As noted above, the freezer system 10 includes a control system 14 tohelp ensure that the freezer system 10 is operating properly and thatthere is no breach of the floor structure 20, sidewalls 22, or ceiling24. To this end, the temperature sensors 150 and 170, the pressuresensor 156, moisture sensor 158, and the dew point sensor 160 are allconnected to the control system by hard wiring, radio frequency, orother wireless transmission means or otherwise. The control systemmonitors the operational parameters of the freezer structure 12 todetermine whether or not such operational parameters are within the setpoints that have been predetermined for these operational parameters.When the operational parameters are within the set points, the freezerstructure 12 is functioning properly.

The control system 14 includes a computer 200 for use in monitoring themonitoring system as well as controlling the circulation system. Thecontrol system also includes a suitable controller 202, such as aprogrammable logic controller linked to the computer and having anappropriate interface 204 for connecting the various sensors andcomponents of the circulation system to the logic controller. A memoryunit 206 is provided for storing information regarding the operation ofthe monitoring system and circulation system. A keyboard or other inputdevice 209 is provided to enable the operator to communicate with thecomputer and/or logic controller. Also, a display or other output device210 is provided to convey information from the computer or controlsystem to the operator, including the functioning of the circulationsystem 18. Rather than employing both a logic controller 202 and acomputer 200, the control system may include only one of thesecomponents. If only a logic controller is used, the logic controllerwill have the needed processing capability required to open to themonitoring system and circulation system. If only a computer is used,then the computer will have the necessary interface between the computerand the sensors of monitoring system and the components of thecirculating system.

The control system 14, more specifically the computer 200 together withthe controller 202, controls the operation of the circulation system. Inthis regard, the temperature and humidity of the air or gas circulatedthrough the hollow layers 30 and 30′ are controlled. The control systemalso controls whether to not the air from the air supply 120 is heated,for example, to thaw ice that may have formed within the hollow layers30 and 30′. The control system also controls whether or not anantibacterial agent is introduced into the air supply circulatingthrough the floor, sidewalls, and ceiling. Further, the control systemcontrols the operation of the steam supply 140 when desired to introducesteam into the hollow layers 30 and 30′, for instance, to clean theinterior of the hollow layers.

In the control system 14, the computer 202 may operate under a processcontrol program to control the operation of the circulation system 18.The process control program may include a specific temperature andhumidity profile that is desired so as to maintain the interior of thehollow layers 30 and 31 in substantially dry condition and prevent theformation of ice or the growth of bacteria or other pathogens. Inaddition, the control system may operate under a process deviationprogram that seeks to adjust one or more system parameters to enable thefreezer structure to operate within preset parameters. In this regard,the control program may utilize one or moreproportional-integral-derivative (PID) controller algorithms, whichfunction to adjust one or more of the temperature and volumetric airsupply to the freezer structure so that moisture does not accumulatewithin the floor, sidewalls, or ceiling and also so that ice does notform therein, and so that bacteria or other pathogens do not growtherein.

Rather than seeking to automatically adjust the operating parameters ofthe circulation system, the control system 14 may instead alertoperators to the deviation of the affected process parameters from thepreselected set point. The system can, in addition, suggest adjustmentsto be made to the temperature and/or flow rate of the circulation air.Thereupon the operator can make the indicated adjustments.

It will be appreciated that the freezer system described aboveadvantageously provides two separate zones under the freezer floorsurface, the freezer side wall surface, and the freezer ceiling surface.The layers or zones directly below the inside surface of the floor,walls and ceiling constitute a conditioned space that allows for themonitoring of temperature and the dew point within such space. Thisspace is continually purged with a supply of very low dew point air tokeep the space not only dry, but also free from ice formation andbacterial growth. This space also has the capability to be steam- orgas-sanitized as required. Through monitoring of this space, theoperator is able to detect critical changes in the integrity of thefloor above the space via change in measurement parameters. The secondzone or layer below the upper or first layer or zone constitutes acompletely sealed, insulated space that will not be impacted if a breachwere to occur in the first or upper zone. Moreover, the third layer orzone below the insulated second zone or layer is monitored fortemperature and moisture. This insulated space is not in direct contactwith the internal floor of the freezer, and thus is subjected to lesssevere thermal stresses than in prior art freezer floor designs.Monitoring of the second zone or space also provides an indication ofthe integrity of the entire freezer structure.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A thermally insulated load-bearing floor system for an industrial refrigeration system, comprising: (a) a floor structure, comprising: (i) a first layer constructed to define a substantially hollow chamber and comprising load-bearing members to support an overhead load-bearing deck; and (ii) a second layer underlying the first layer and constructed to support and carry the load carried by the load-bearing deck on said first layer, said second layer being substantially occupied by a thermally insulating material; (b) said floor structure constructed to isolate the first layer from the second layer comprising a continuous interface between the first layer and the second layer; (c) a fluid circulation system to circulate selected fluids through the first layer, said selected fluids selected from a group consisting of: a gas or gas mixture to assist in maintaining the first layer in a substantially dry condition; a fluid to sterilize the first layer and/or maintain the first layer in a sterilized condition; and a fluid to assist in thawing ice formed in the first layer; and (d) a monitoring system for monitoring one or more of the temperature, pressure, and moisture levels in the first layer.
 2. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein the circulating fluid comprises one or more of the following: dry, low dew point air; steam; air, together with an anti-bacterial agent; an inert gas.
 3. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein said monitoring system senses one or more of: the dew point of the fluid within the first layer; the volume of the fluid circulating through the first layer; and the pressure of the fluid circulating through the first layer.
 4. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein said monitoring system monitors the temperature beneath the second layer.
 5. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein said floor structure defines a third layer beneath the second layer, said third layer extending between the underside of the second layer and a surface beneath the second layer.
 6. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 5, wherein said third layer is formed by spacer members underlying the second layer.
 7. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein said second layer is substantially sealed from the exterior.
 8. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein said thermally insulating material is encased within a fluid impervious sealed envelope.
 9. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 8, wherein the thermally insulating material is sealed within an outer layer composed of a material selected from foil and Mylar.
 10. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein the thermally insulated material is selected from a group comprising polyisocyanurate, polyurethane, and polystyrene.
 11. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein said first layer comprises load-bearing members extending therethrough for supporting the load-bearing deck and remaining beneath the load-bearing deck.
 12. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, wherein: the second layer is substantially isolated from the first layer, at least in part by a first barrier wall between the first and second layers; and the thermally insulated material is enclosed in a fluid-impervious envelope.
 13. A thermally insulated load-bearing floor system for an industrial refrigeration system, comprising: (a) a floor structure, comprising: (i) a first layer constructed to define a substantially hollow chamber and comprising load-bearing members to support an overhead load-bearing deck; and (ii) a second layer underlying the first layer and constructed to support said first layer, said second layer being substantially occupied by a thermally insulating material, wherein: the second layer is substantially isolated from the first layer, at least in part by a first barrier wall between the first and second layers; and the thermally insulated material is enclosed in a fluid-impervious envelope; (b) said floor structure constructed to isolate the first layer from the second layer; (c) a fluid circulation system to circulate selected fluids through the first layer, said selected fluids selected from a group consisting of: a gas or gas mixture to assist in maintaining the first layer in a substantially dry condition; a fluid to sterilize the first layer and/or maintain the first layer in a sterilized condition; and a fluid to assist in thawing ice formed in the first layer; (d) a monitoring system for monitoring one or more of the temperature, pressure, and moisture levels in the first layer; and (e) a second barrier wall underlying the thermally insulated material, with the thermally insulated material spaced above the second barrier wall to form a substantially hollow third layer beneath the second layer.
 14. The thermally insulated load-bearing floor system for an industrial refrigeration system according to claim 1, comprising: (a) a floor structure, comprising: a first layer constructed to define a substantially hollow chamber and comprising load-bearing members to support an overhead load-bearing deck; and (ii) a second layer underlying the first layer and constructed to support said first layer, said second layer being substantially occupied by a thermally insulating material; (b) said floor structure constructed to isolate the first layer from the second layer; (c) a fluid circulation system to circulate selected fluids through the first layer, said selected fluids selected from a group consisting of: a gas or gas mixture to assist in maintaining the first layer in a substantially dry condition; a fluid to sterilize the first layer and/or maintain the first layer in a sterilized condition; and a fluid to assist in thawing ice formed in the first layer; (d) a monitoring system for monitoring one or more of the temperature, pressure, and moisture levels in the first layer; and (e) wherein the thermally insulated material comprising a top surface facing the first layer and a bottom surface facing away from the first layer; a barrier wall underlying the bottom surface of the thermally insulating material; and the bottom surface of the thermally insulating material is spaced from the barrier wall to form a substantially hollow third zone.
 15. An industrial freezer, comprising: (a) a first layer adjacent the interior of the freezer and constructed to define a substantially hollow chamber and carry a load applied against the interior of the freezer; (b) a second layer disposed outwardly from the interior of the freezer relative to the first layer, said second layer being substantially occupied by a thermally insulating material, said second layer being isolated from the first layer, said second layer constructed and positioned to support and carry the load applied to the first layer; (c) a fluid circulation system to circulate a substantially dry gas through the first layer at a flow rate to maintain the first layer in a substantially dry condition; and (d) a monitoring system to monitor one or more of the temperature, pressure, and moisture level in the first layer.
 16. The industrial freezer according to claim 15, wherein: the first and second layers comprise a floor structure of the freezer; the freezer further comprising upright walls that join to the floor structure, and wherein the interior of the upright walls are in fluid flow communication with the interior of the first layer of the floor structure.
 17. The industrial freezer according to claim 16, wherein the first layer further comprises: a deck extending over the first layer; and load-bearing members to support and carry the deck, the load-bearing members remaining below the deck.
 18. The industrial freezer according to claim 16, further comprising a third layer disposed beneath the second layer, said third layer comprising spacer members that underlie the second layer to space said second layer above a surface beneath the second layer.
 19. The industrial freezer according to claim 15, wherein the first and second layers comprise one or more of the floor structure of the freezer, the walls of the freezer, and the ceiling of the freezer.
 20. The freezer according to claim 19, wherein the first layers of the one or more of the floor structure, walls, and ceiling are in fluid flow communication. 